Zenaji Aeon A48-40 User manual
Aeon Battery
A48-40
Installation Manual
Pty. Ltd.
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 3
• Information within this guide is accurate at the time of
publication and is subject to change without notice.
• Illustrations and images are only for the purpose of
assisting with installation and system conguration and
for illustration purposes only.
• Read this documentation in its entirety before
installation.
• Retain a copy of this document for reference purposes.
• Once complete, give this document to the customer for
their reference purposes
pg. 4 | Zenaji Australia Pty Ltd
Contents
1 Information about this document......................................................................6
1.1 Target group...............................................................................................6
1.2 Product Designation...................................................................................6
1.3 Glossary of Terms........................................................................................6
1.4 TermsandConditions..................................................................................7
1.4.1 Installation.......................................................................................7
1.4.2 Standards.........................................................................................7
1.4.3 VoltageLimits...................................................................................7
2 Safety......................................................................................................................8
2.1 Intended use................................................................................................8
2.2 Installer Requirements...............................................................................8
2.3 General Safety Precautions........................................................................8
2.4 Battery Handling..........................................................................................9
2.5 Hazards.........................................................................................................9
2.6 Markings & Symbols..................................................................................10
2.7 Emergency Response................................................................................11
3 Product Overview................................................................................................12
3.1 Technical information..............................................................................12
3.2.1 Dimensions and Weight................................................................12
3.2.2 Specications................................................................................14
3.2.3 State of Charge Graph..................................................................15
3.3 Features.....................................................................................................16
3.3.1 Circuit breaker...............................................................................17
3.3.2 Connection Cable..........................................................................18
3.3.3 Additional Mounting Points.........................................................18
3.4 Additional Devices and Accessories.......................................................19
3.4.1 Additional Devices........................................................................19
3.4.2 Accessories....................................................................................19
3.5 Environmental Conditions.......................................................................20
3.5.1 Installation & operation Conditions.............................................20
3.5.2 Storage and Transport Conditions..............................................20
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 5
4 Installation..........................................................................................................22
4.1 Minimum distances..................................................................................22
4.1.1 Distances from power equipment.............................................22
4.1.2 Distances from walls, vents & other equipment......................23
4.2 Mounting the Battery...............................................................................24
4.2.1 Mounting to a wall........................................................................24
4.2.2 Wall Mounting Plate.....................................................................26
4.3 Connecting and commissioning the battery.........................................27
4.3.1 Inverter Settings...........................................................................27
4.3.2 Connecting a single battery........................................................27
4.3.3 Multiple Batteries.........................................................................27
4.3.4 Adding a battery to an existing Zenaji battery system............28
4.3.5 Earthing the battery......................................................................29
4.3.6 Inverter Settings - Commissioning..............................................29
4.3.7 Initial Charge.................................................................................30
5 Battery Maintenance........................................................................................32
5.1 Battery Periodic Maintenance.................................................................32
5.2 Isolation Procedure..................................................................................32
5.3 Shutdown Procedure...............................................................................32
6 Uninstallation & Return..................................................................................33
6.1 Uninstallation for Repair or Return........................................................33
6.2 Disposal.....................................................................................................33
7 Troubleshooting................................................................................................34
8 Battery & Cell Designation Information.....................................................36
9 Registration & Installer Agreement.............................................................37
9.1 Installer Details.........................................................................................37
9.2 Qualied Personnel Agreement & Notes...............................................38
10 Contact................................................................................................................39
pg. 6 | Zenaji Australia Pty Ltd
1
INFO
1 Information about this document
1.1 Target group
This document is intended for Qualied Personnel and any action described in this document
must be carried out by qualied personnel.
1.2 Product Designation
This document designated for the following Zenaji Products.
A48-40
1.3 Glossary of Terms
Read this summary of terms before reading the remainder of the manual.
Power Equipment: This refers to an electronic device an Aeon battery can be connected to
that can charge and/or discharge the battery. Most commonly this will be a Battery Charger/
Inverter or Hybrid Solar Inverter used with a solar photovoltaic power system for a house.
Battery: In this document refers to one 1.93kWh Aeon Battery.
Battery System: A battery or group of batteries connected to a single piece of power
equipment or multiple power equipment that is connected together.
Installed Battery: A battery that is part of a battery system, already installed, commissioned
and in use.
Additional Battery: A battery that is to be added to a previously commissioned battery
System.
Commission: To begin the use of a battery system, after installing the batteries and the
circuit breakers have been switched to ON.
Qualied Personnel: Personnel who have completed the required training and are certied
to undertake electrical works in their state.
Load weight: The total weight of a battery system on the supporting wall.
Self-managed battery: A battery which contains its own cell balancing and protection
equipment.
LTO: Lithium Titanate, the cell chemistry used in Zenaji Aeon Batteries
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 7
1
INFO
1.4 Terms & Conditions
When installing and operating the Aeon battery the following Terms & Conditions must be
met. Failure to comply will void any warranty provided by Zenaji.
1.4.1 Installation
Installation must be carried out by qualied personnel.
1.4.2 Standards
The Aeon battery must be installed according to current local authority standards. In
Australia and New Zealand these include but are not exclusive to:
AS/NZS 5139:2019
AS/NZS 3000
1.4.3 Voltage & Current Limits
The Power Equipment which charges and discharges the Aeon Battery must not bring the
voltage of the battery above 56.5V or below 42V. The maximum allowable continuous current
should not be set above 50A per battery connected to the Power Equipment.
pg. 8 | Zenaji Australia Pty Ltd
2
SAFETY
2 Safety
2.1 Intended use
The Aeon Battery is a nominal 48V LTO self-managed battery intended for use with power
equipment to store and provide electrical energy. Improper use or handling poses risk of
death or injury to the user or third parties as well as damage to the battery or other items of
value, especially power equipment the battery is connected to.
The following must be observed to comply with use of this product:
• The battery must be installed according to the installation instructions.
• The battery must be installed by qualied personnel.
• The battery must be used in a suitable location.
Failure to comply to these conditions or warranty conditions invalidates any warranty claims.
2.2 Installer Requirements
Installers are responsible for reading and understanding this document before installation
1. The battery must be installed by qualied personnel. Qualied personnel must be a
qualied electrician and considered competent and registered to work to the AU/NZS
3000:2018 safety standard, or equivalent local authority safety standard where outside of
Australia and New Zealand.
2. To install the battery according to Australian Battery Safety Standards AS/NZS 5139:2019
or equivalent local authority standards.
3. For Zenaji to provide the “20 year, 22,000 Cycle Warranty” the installer must register the
battery after installation.
2.3 General Safety Precautions
• Over-voltages or incorrect wiring can damage the battery or connected equipment.
• Avoid installing the battery in locations where ammable materials are present.
• Do not install in locations where explosive chemicals or gasses are present.
• Installation must be carried out by Qualied Personnel.
• Battery is not user serviceable.
• Inspect battery for any damage prior to installation.
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 9
2
SAFETY
2.4 Battery Handling
• Ensure circuit breaker on the base of the battery is set to OFF when handling,
transporting, connecting or disconnecting the battery.
• Two person lift, 36kg (39kg net packaged), ensure any lifting calculations are carried
out as according to state regulations.
• Do not expose battery to open ame.
• Do not expose battery to temperatures over 60°C
• Do not damage the unit in any ways physical such as crushing, dropping, piercing
with a sharp object, impacting. This may cause leakage of electrolyte or short circuit
with the risk of re.
• Do not connect positive and negative wires to each other causing a short circuit.
• Do not charge or discharge damaged battery.
• Do not place the battery with the connection cable on the ground.
• Unqualied personnel are not to disconnect, disassemble or repair the battery.
Services must be made by Qualied Personnel only.
• Ensure Connection cables ends are not exposed prior to nal connection to power
equipment.
• Keep out of reach of children and animals
• All wiring must be protected from intrusion and cutting.
• Store the battery in a dry place.
• Ensure temperature is maintained between -5°C to 35°C when handling or
transporting the battery (recommended 20°C to 30°C).
• No foreign object is to be placed on top of the battery.
• Only use battery with Zenaji authorised power equipment.
• Do not immerse in water.
2.5 Hazards
Leaking electrolyte and gases can cause irritation and harm.
• Skin: On contact, the electrolyte solution contained in the battery causes irritation
to skin. Symptoms include irritation and burns.
• Eyes: On contact, the electrolyte solution contained in the battery or gases released
due to battery damage cause irritation to ocular tissue and skin around the eyes.
Symptoms include irritation, redness, tearing and burns. The electrolyte is corrosive
to all ocular tissues.
• Inhalation: Gases due to high heat or abundance of leaking batteries cause burns
of the respiratory system. Symptoms include coughing, wheezing, and shortness of
breath.
• Ingestion: The ingestion of the battery is harmful. Content of the battery can cause
serious chemical burns to the mouth, oesophagus and gastrointestinal tract.
pg. 10 | Zenaji Australia Pty Ltd
2
SAFETY
2.6 Markings & Symbols
The images below show the symbols and markings found on the top and bottom covers of
the battery. This gives critical battery information which is also provided in the installation
manual.
Current:
CHARGE INSTRUCTIONS
Maximal Charge:
Float Charge:
Minimal Discharge:
57V
55.5V
42V
50A
DO NOT OPEN
Designed & Made in Australia
Type: Rechargeable Li-ion Battery System
Capacity Rated/Calculated: 40Ah/40Ah x 48.3V = 1930Wh
IP65 -40°C to 60°C
Nominal Voltage/Capacity: 48.3V/40Ah
Rated Current: Charge & Discharge 1.25C(Max)
Designation: XXR/66/160/[24S]L/-40+60/95
Protective class: I
SERIAL : ZENA48-03-2010-0001
Zenaji Pty Ltd
48V DC
RED
BLACK
DO NOT OPEN
CAUTION DO NOT OPEN
This symbol indicates the battery should not be opened and
opening could result in a hazardous situation resulting in
injury, if not avoided.
Do not dispose of the battery with domestic waste.
For further information on disposal, refer to section 6.1 of
this manual.
Zenaji Pty Ltd
48V DC
RED
BLACK
This marking indicates the installation manual contains information, processes and
procedures that must be read and followed in the installation and operation of the
battery and must be read prior to installation and operation of the battery.
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 11
2
SAFETY
2.7 Emergency Response
If exposed to leaking electrolyte from ruptured or leaking battery the following actions are
recommended
• Skin Contact: If the battery is leaking and the contained material contacts skin,
ush with copious amounts of clear water for at least 15 minutes.
• Eye Contact: If the battery is leaking and the contained material contacts eyes,
ush with copious amounts of clear water for at least 15 minutes. Seek medical
attention immediately.
• Inhalation: If the battery is leaking, leave the contaminated area to fresh air. If
irritation persists, seek medical attention.
• Ingestion: If the battery is leaking and the contained material is ingested, rinse
the mouth and surrounding area with clear water at once. Seek medical Attention
immediately.
Fire Fighting Measures
• If re occurs when charging or discharging the batteries, if it is safe to do so, shut
o the power to the battery.
• Extinguishing Media – Dry chemical type extinguishers are the most eective means
to extinguish a battery re. A CO2 extinguisher will also work eectively.
• Fire Fighting Procedures – Use a positive pressure self-contained breathing
apparatus batteries are involve in a re. Full protective clothing is necessary. During
water application, caution is advised as burning pieces of ammable particles may
be ejected from the re.
Accidental release
• In the event of rupture and leakage, collect all released material that are not
burning or hot in an appropriate waste disposal container while wearing proper
protective equipment and ventilate the area. Dispose according to local regulations.
pg. 12 | Zenaji Australia Pty Ltd
3
PRODUCT
3 Product Overview
3.1 Technical Information
3.2.1 Dimensions & Weight
Battery
Width – 160mm
Depth – 150mm
Height – 1635mm
Weight – 36kg
Cable & Gland
Diameter – 30mm
Cable bend radius allowance from base of battery – 60mm minimum
160
60
115
99.6
R16 Gland
120
Cable bend Allowance
160
60
115
99.6
R16 Gland
120
Cable bend Allowance
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 13
3
PRODUCT
160
1647
(includes cable gland)
1635
150
115
99.6
R16
120
pg. 14 | Zenaji Australia Pty Ltd
3
PRODUCT
Specication Value
Nominal Capacity (25°C ± 5°C) (Useable Capacity) 1.93KWh (40Ah)
Chemistry Lithium Titanate (LTO)
Dimensions (Height x Width x Depth) 1635 x 155 x 145 mm
Nominal Voltage 48.3V
Charge Cut-o Voltage (Bulk/Absorption Voltage)* 56.5V
Float Voltage* 55.5V
Discharge Cut-o Voltage (Low Cut-o Voltage)* 42V
Low Restart Voltage (Reconnect Voltage)* 44.6V
Mass 36kg
Rated DC Charge/Discharge Current (25°C ± 5°C) 50A (1.25C) continuous DC, 38A (0.95C) pulsed
DC**
Rated DC Charge/Discharge Power (25°C ± 5°C) 2415W continuous DC, 1835W pulsed DC**
Max DC Charge/Discharge Current (10s, 25°C ±
5°C) 120A (3C)
Max DC Charge/Discharge Power (10s, 25°C ± 5°C) 5796W
Battery Management System
Internal cell balancing, failure detection and trip.
Under-Voltage, Over-Voltage, Over-Current, Over-
Temp, Under-Temp protection and trip
Isolation & Distribution Block Requirement 50A per battery connected in parallel
Battery Short Circuit Current 1700A
Operating Temperature -40°C to 60°C (recommended 5°C to 35°C)
Storage Temperature -5°C to 35°C
Cycle Life (1C, 25°C ± 5°C) 22,000
Depth of Discharge 100%
Round Trip Eciency (1C, 25°C ± 5°C) 96%
Ingress Rating IP65
Installation Indoors or outdoors
Connections 8mm² (8 AWG) (Ø3mm) wire per pole
Warranty 20 Years or 22,000 cycles, whichever comes rst,
see warranty document for details
3.2.2 Specications
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 15
3
PRODUCT
3.2.3 State of Charge Graph
The graph below shows a guide to the State of Charge to Capacity of an A48-40 Aeon battery
during Charge (Red) and Discharge (Blue).
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
0 10 20 30 40 50 60 70 80 90 100
0 2010 30 40 50 60 70 80 90 100
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
Capacity %
Voltage V
ChargeDischarge
A48-40 SOC Voltage to Capacity % Graph
pg. 16 | Zenaji Australia Pty Ltd
3
PRODUCT
3.3 Features
M8 Mount & Earth Point
section 3.3.3
Circuit Breaker
section 3.3.1
Connection Cable
section 3.3.2
M8 Mount & Earth Point
section 3.3.3
STATUS LED
section 6
Circuit breaker
lock point
M8 Mount & Earth Point
section 3.3.3
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 17
3
PRODUCT
3.3.1 Circuit breaker
Circuit Breaker: CBi-Electric C Frame MKIV - AS Current Rating Curve (shown below)
• The circuit breaker is located at the base of the battery next to the cable.
• When On the ON switch will be at and current can ow, when O the ON button will be
raised and current cannot ow.
• The circuit breaker is dual pole
• The circuit breaker has a nominal DC rating of 50A, refer to the rating curve below for
more detail
Circuit Breaker - ON Circuit Breaker - OFF
pg. 18 | Zenaji Australia Pty Ltd
3
PRODUCT
3.3.2 Connection Cable
As standard, each battery is tted with a 2m length of dual core 8 AWG (Ø3mm) cable. The
cable will need to be stripped prior to connection.
• Where possible, do not cut cables.
• In the event cables must be shortened, all batteries must be of equal length and
never shortened to less than 1000mm.
The RED cable is the POSITIVE connection.
The BLACK cable is the NEGATIVE connection.
A
2000mm ±50mm
DETAIL
A
SCALE
1 : 2
160
1647
(includes cable gland)
1635
150
115
99.6
R16
120
M8 Mounting Locations
3.3.3 Additional Mounting Points
Where the provided mounting plate and
brackets are not suitable for installation a
custom mounting system can be used.
6 mounting points are provided for
this purpose, 3 at the top and 3 at the
bottom. Dimensions for these are to the
right.
Any custom mounting system must be
rated to a carry a gross load of 40kg.
Aeon Battery Installation Manual V3.1 APR 2021 | pg. 19
3
PRODUCT
3.4 Additional Devices and Accessories
3.4.1 Additional Devices
Distribution blocks, bus bars or terminal blocks (one per pole) must be used when connecting
more than one battery to power equipment. Zenaji recommends a 300A or higher rated
block be used to allow for exibility of the installation.
The M8 Countersunk Bolts provided require a T40 Security (Tamper-proof) Torx bit, these are
available at your local tool or hardware shop.
3.4.2 External Protection Devices
Additional information for selecting and connecting external protection devices to the Aeon
Battery.
Output Short circuit current - 1700A
Maximum Allowable Prospective Short Circuit Current - 1700A
Minimum Required Prospective Short Circuit Current - 50A
Aeon Battery Overvoltage Category - III
3.4.2 Accessories
Included with each battery are brackets to allow mounting of the battery to a wall or other
structure and an Earthing kit for earthing the battery when required.
2x Mounting Plates
4x M8x20mm Countersunk Socket
Head Bolts
(5mm Hex Bit or Allen Key required -
not provided)
Top Mounting Hook Bottom Mounting Hook
Earthing Kit
(M5 Screw, M5 Lock Washer, 6mm² Earth Cable)
pg. 20 | Zenaji Australia Pty Ltd
3
PRODUCT
3.5 Environmental Conditions
3.5.1 Installation & Operation Conditions
The Aeon Battery must be kept in sheltered conditions described as 3K7 low/3Z2/3Z6/3Z7/3
Z8/3B2/3C2(3C3)/3S3/3M5(3M3) in IEC 60721-3-3 for installation & operation. A summary of
these conditions and additional information is below.
• Indoors or Outdoors
• No direct sunlight
• No excessive heat radiation close by <600 W/m2, a minimum distance of 600mm
from any heat source
• No excessive water spray
• Pollution levels kept to normal levels
• Location protected from seismic shock
• Free from corrosive and explosive gases
• No coolant required
• Ambient Temperature between -40° to 60°C
• Wall or surface is suitable for heavy loads
• Applicable local building codes must be observed
• Well Ventilated space, if indoors the space must be ventilated
3.5.2 Storage & Transport Conditions
The Aeon Battery must be kept in Temperature-controlled locations as described as 3K3/3Z
2/3Z4/3B1/3C2(3C1)/3S2/3M1 in IEC 60721-3-3 for storage & transport. A summary of these
conditions and additional information is below.
• No direct sunlight
• No excessive heat radiation close by <600 W/m2, a minimum distance of 600mm
from any heat source
• No water spray or dripping
• Pollution levels kept to normal levels
• Location protected from seismic shock & excessive vibration
• Free from corrosive and explosive gases
• No coolant required
• Ambient Temperature between 5° to 45°C
• Well Ventilated space
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